Urethane Protective Layer for Soft Tactile Transfer Sheets
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Solution Overview
Problem
Existing transfer sheets and decorative sheets fail to provide a soft tactile impression while also experiencing issues with cuttability and foil burrs when attempting to enhance softness, as they rely solely on surface shape without using a soft material for the protective layer.
Innovation Solution
A transfer sheet with a release layer containing particles, a protective layer made of ionizing radiation-curable urethane resin with Martens hardness between 2.0 to 40.0 N/mm2, and an adhesive layer containing acrylic resin, which imparts a smooth and soft tactile impression while minimizing foil burrs by maintaining sufficient hardness and cuttability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the film thickness of the protective layer is increased to enhance softness, then the soft tactile impression is improved, but the cuttability of the transfer layer is deteriorated and excessive transfer layer remains around the resin molded article
Solution Approach 1:
The patent changes the material parameters of the protective layer by specifying Martens hardness of 2.0 to 40.0 N/mm² and using ionizing radiation-curable urethane resin, which provides softness without requiring excessive thickness increase, thus maintaining cuttability
Solution Approach 2:
The patent uses a composite structure combining ionizing radiation-curable urethane resin with specific particle compositions in the release layer, creating a protective layer that achieves both softness and adequate cuttability through material composition rather than thickness alone
2Ease of operation
If a soft material is used for the protective layer to achieve soft tactile impression, then the softness is improved, but the cuttability is deteriorated and foil burrs are generated
Solution Approach 1:
The patent specifies precise parameter ranges including Martens hardness of 2.0 to 40.0 N/mm² and surface roughness Ra of 0.15 to 1.0 μm, which optimize the balance between softness and cuttability to prevent foil burr formation
Solution Approach 2:
The patent uses particles with specific size distributions (D10: 0.5 to 5.0 μm, D50: 1.0 to 10.0 μm, D90: 2.0 to 20.0 μm) in the release layer to create localized surface features that provide softness while maintaining overall cuttability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively provides a smooth and soft tactile impression while preventing foil burrs, as the urethane resin-based protective layer offers durability and flexibility, and the acrylic adhesive layer ensures clean peeling and reduced burr formation.
Implementation Method 1
a protective layer containing an ionizing radiation-curable urethane resin
Data Source
AI summary
A transfer sheet includes, on a base sheet, at least a release layer containing particles and having a surface roughness Ra of 0.15 to 1.0 μm, a protective layer containing an ionizing radiation-curable urethane resin and having a Martens hardness of 2.0 to 40.0 N/mm2, and the adhesive layer containing an acrylic resin, that are laminated in this order. A decorative sheet is formed by transferring the transfer sheet on a support sheet. A decorative article is a resin molded article decorated by using the transfer sheet or the decorative sheet.